Typical Results achieved were:

1. 5S Level improved from 47% to 72%
2. Quality Level improved from 900 DMP to 430 DMP
3. Inventories reduced from Rs. 25 Cr. to Rs. 13 Cr
4. zero accidents from original level of 2 accidents per month on an average
5. much space savings
Implementation of 268 nos. of Kaizens
6. Organized Stores with built-in FIFO etc

Results achieved were:

1. Clean, tidy and Visual Shop
2. 25% reduction in direct manpower
3. 40% increase in productivity
4. 25%-30% reduction in WIP inventories
5. ease of storage and material handling

Activities taken up were:

1. Removal of excess machines, materials, work tables etc
2. Relocating of some of the machines and work stations
3. Organizing storage of WIP’s defining norms
4. Relaying out of FG Stores with built-in FIFO system
5. Deployment of Water Spider System for material feeding
6. Adoption of proper 5S & Visual control for materials, tools etc

Typical results were:

1. Organized Stores with 5S & Visual Control in place
2. Disposing off of Non-Moving / Dead Stocks to the extent possible
3. Accounting all cases concerning Excess Inventories and better control of Purchases
4. Proper Stacking of all items with concept of 3- Fixed
5. Up-gradation of Racks, Shelves, Bins etc
6. Safety of Materials thru’ effective use of “USE ME FIRST” Tags apart from better stacking
7. Pouching for ease of counting, stacking and issue of smaller parts and hardware’s
8. Driving improvement of packaging at suppliers’ ends etc

As per latest information, inventories have come down to well below Rs. 200 Crores which means over 20% reduction.

Results achieved were:

1. Clean, tidy & a Visual Warehouse
2. In-built FIFO
3. Increase of Productivity by 40-60%
4. Sharp reduction in Customer Complaints
5. Implementation of Quantity Control for effective Inventory Management

Typical activities taken up were:

1. Cycle Time study & improvement
2. Rationalizing work contents of operators for better utilization
3. Material feeding frequently @ one hour by Water Spider
4. Hourly feeding of materials deploying Water Spider
5. Improvement in packaging of outsourced items to facilitate direct material feeding
6. Employing concept of 3-Fixed in Stores including adoption of FIFO Tags & Quantity Control System
7. Avoiding wastes in material feeding by adopting direct feeding instead of multiple material handling
8. Streamlining Packaging & Dispatch process etc

Objectives were:

1. To make a model flow production line with rabbit-chase concept
2. To increase productivity by 30-50%
3. To reduce quality problems by 30-40%
4. To minimize WIP inventories
5. To achieve top-class 5S & Visual Control
6. To save space by 20-30%

Achievements were implementation of model flow line, excellent 5S & Visual Control, more than 100% increase in productivity, reduction in rejections & reworks by 50%, reduction of WIP inventories from 10 hours to 1-hour, and savings in space by 50%.

Additional achievements were:

1. creation of BOM, Control Plans and SOP’s
2. training of people on quality and lean tools and techniques

Project was to help establish a Ceiling Fan Manufacturing set up with Lean Concept—from concept to commissioning. Typical deliverables were:

1. Overall Inventories of less than 10 days
2. Half the Space Occupied
3. World-class material handling and storage system, etc. All these are over comparable Indian Industries